WO2000019001A1

WO2000019001A1 - Apparatus and method for cleaning and refreshing fabrics with a supplemental heat source

Info

Publication number: WO2000019001A1
Application number: PCT/US1999/022372
Authority: WO
Inventors: Bruce Albert Yeazell; Johh Michael Jensen; Matthew Edward Volpenhein
Original assignee: The Procter & Gamble Company
Priority date: 1998-09-28
Filing date: 1999-09-28
Publication date: 2000-04-06
Also published as: JP2002525187A; EP1117863A1; CN1318118A; CA2341394A1; BR9914082A; AU1096300A

Abstract

An apparatus for treating fabrics that comprises a fabric treatment bag having side panels configured such that they define an interior chamber of the treatment bag such that at least one fabric article can be suspended in the interior chamber. A liquid cleaning/refreshment composition is placed in or adjacent the fabric treatment bag such that the vapors from the cleaning/refreshment composition enter the interior chamber of the treatment bag, and the treatment bag is subjected to a supplemental heat source. Preferably the supplemental heat source is passive, and even more preferably the passive source of heat is selected from the group consisting of solar radiation, a particulate exothermic composition and mixtures thereof. Methods of using the apparatuses of this invention to clean and refresh fabric articles are also provided.

Description

APPARATUS AND METHOD FOR CLEANING AND REFRESHING FABRICS WITH

A SUPPLEMENTALHEAT SOURCE

TECHNICAL FIELD The present invention relates to apparatuses and methods useful for cleaning and refreshing fabrics in a non-immersion cleaning process that uses a supplemental heat source that is preferably a passive heat source.

BACKGROUND OF THE INVENTION

Certain delicate fabrics are not suitable for conventional in-home immersion cleaning processes. Home washing machines, which provide excellent cleaning results for the majority of fabrics used in today's society, can, under certain conditions, shrink or otherwise damage silk, linen, wool and other delicate fabrics. Consumers typically have their delicate fabric items "dry- cleaned". Unfortunately, dry-cleaning usually involves immersing the fabrics in various hydrocarbon and halocarbon solvents that require special handling and the solvent must be reclaimed, making the process unsuitable for in-home use. Hence, dry-cleaning has traditionally been restricted to commercial establishments making it less convenient and more costly than in- home laundering processes.

Attempts have been made to provide in-home dry-cleaning systems that combine the fabric cleaning and refreshing of in-home, immersion laundering processes with the fabric care benefits of dry-cleaning processes. One such in-home system for cleaning and refreshing garments comprises a substrate sheet containing various liquid or gelled cleaning agents, and a plastic bag. The garments are placed in the bag together with the sheet, and then tumbled in a conventional clothes dryer. In a current commercial embodiment, multiple single-use flat sheets comprising a cleaning/refreshing agent and a single multi-use plastic bag are provided in a package.

Unfortunately, such in-home processes are designed for use in a conventional clothes dryer, or the like apparatus. Such apparatuses are not always readily available, and they are often uneconomical. Moreover, in many countries clothes dryers are simply unnecessary. For example, in many warm tropical regions people do not typically own clothes dryers because their clothes can be dried year-round by hanging them outside in the sun. In the areas of the world where people do not typically own clothes dryers, products that require a heating apparatus, such as a clothes dryer, are of little or no value.

Thus, there is a need to develop a domestic, non-immersion cleaning and refreshing process, and cleaning and refreshing compositions for use therein, which provide acceptable cleaning without the need for a mechanical, electrical or combustion heat source.

It has now also been unexpectedly discovered that certain heat sources such as solar radiation and/or chemical oxidation reactions, can be employed with a cleaning/refreshment composition and a fabric treatment bag during a domestic, non-immersion cleaning/refreshment process to effectively clean and refresh fabrics. The present invention provides apparatuses, methods for using those apparatuses, and kits containing the apparatuses for cleaning and refreshing fabrics without the need for mechanical, electrical, or combustion heat sources.

SUMMARY OF THE INVENTION In one aspect of the present invention there is provided an apparatus for treating fabrics comprising: a) a fabric treatment bag having side panels configured such that they define an interior chamber of the treatment bag such that at least one fabric article can be suspended in the interior chamber; b) a liquid cleaning/refreshment composition; and c) a passive source of heat.

The passive source of heat is preferably selected from the group consisting of solar radiation, a particulate exothermic composition and mixtures thereof. The particulate exothermic composition preferably comprises iron powder, carbon, at least one metal salt, and water.

In one preferred embodiment of this invention, the cleaning/refreshment composition is releasably absorbed in a substrate. In yet another aspect of this invention the apparatus further comprises a dosing device for containing the cleaning/refreshment composition.

The present invention also provides a non-immersion cleaning/refreshment process for treating a fabric article comprising the steps of:

(a) placing the fabric article together with a cleaning and refreshing composition in an interior chamber of a fabric treatment bag;

(b) subjecting the fabric treatment bag to a passive source of heat; and

(c) removing the fabric from the fabric treatment bag. Preferably, vapors are vented from the fabric treatment bag during step (b) in the above process. And in a preferred aspect of this process the fabric article has a first side and a second side and the process further comprises the steps of:

(a) applying a spot cleaning composition from a dispenser to a discrete stained area of the first side of the fabric;

(b) concurrently or consecutively with Step (a), contacting the first side of the fabric adjacent the stained area with a treatment member; and

(c) contacting the second side of the fabric adjacent the stained area with an absorbent stain receiving article.

The present inventions provide benefits over the prior art in that fabric articles can be cleaned and refreshed without the need for expensive mechanical apparatuses, such as a clothes dryer. Moreover, when solar energy is used as the passive heat source, there is no energy cost to the consumer.

BRIEF DESCRIPTION OF THE DRAWINGS

While this specification concludes with claims that distinctly define the present invention, it is believed that these claims can be better understood by reference to the Detailed Description Of The Invention and the drawings, wherein:

Figure 1 is a schematic representation of a fabric treatment bag according to the present invention;

Figure 2 is schematic representation of a fabric treatment bag according to the present invention wherein a portion of one corner is cut away for a view of a substrate;

Figure 3 is a partial schematic representation of the lower portion of a fabric treatment bag according to the present invention wherein a supplemental heat source is laid under a substrate;

Figure 4 is a partial schematic representation of the bottom portion of a fabric treatment bag according to the present invention wherein a pouch for receiving a substrate is placed on a side panel of the treatment bag; and

Figure 5 is a schematic representation of a fabric treatment bag according to the present invention wherein the side panels are clear and no vents are provided in the lower portion of the, treatment bag. DETAILED DESCRIPTION OF THE INVENTION The present invention provides an apparatus for cleaning and refreshing fabric articles in a domestic, non-immersion process that utilizes a supplemental heat source that is preferably a passive heat source. The cleaning and refreshing of the fabric articles is carried out in a fabric treatment bag with a cleaning and refreshing composition that can be added into the treatment bag directly, for example, by pouring it into a pouch, spraying it, or pouring it into a dosing device that is placed in the treatment bag. Or it can be added to the treatment bag via a substrate wherein the cleaning and refreshing composition is releasably absorbed.

The passive heat source, which can be inside, outside or adjacent the treatment bag, causes the cleaning and refreshing composition to at least partially vaporize. The vapors then intermingle with the fabric articles to clean and refresh the fabric. The vaporized cleaning and refreshing composition, along with malodorous compounds and other volatile matter, are preferably vented through the upper portion of the treatment bag. Treatment bags, cleaning and refreshing compositions, passive heat sources, and methods of using theses items in a domestic, non-immersion cleaning and refreshing process are all described in greater detail below.

Fabric Treatment Bag

Figure 1 is a schematic representation of a fabric treatment bag 10 according to the present invention, wherein treatment bag 10 has a height 12, a width 13, and a depth 14. It is understood that while treatment bag 10 is shown in a rectangular box configuration, the present invention is not meant to be so limited. Other structural configurations are appropriate for this invention, for example, pyramid, spherical, hemi-spherical, two sided/garment bag and other configurations. The treatment bag can be any appropriate size. Preferred dimensions for treatment bag 10 are as follows: height 12 is preferably from about 40 cm to about 200 cm, more preferably, from about 50 cm to about 150 cm; width 13 is preferably from about 30 cm to about 100 cm, more preferably, from about 40 cm to about 80 cm; and depth 14 is preferably from about 0 cm to about 100 cm, more preferably, from about 10 cm to about 80 cm.

Treatment bag 10 preferably comprises side panels 21 that define an interior chamber 23, which can be accessed via opening 15. Opening 15 should be covered during operation of treatment bag 10 and this can be accomplished with access panel 19, which is sealed to side panel 21 with seal 17. Those skilled in the art will recognize that there are a variety of methods for gaining access to the interior chamber 23 of the treatment bags of this invention, and one such alternative if shown in Figure 2. Seal 17 can comprise virtually any known sealing device such as zippers, tape, ZIP LOCK® seals and hook and loop type fasteners, for example VELCRO®.

Treatment bag 10 can be constructed from any appropriate materials, such as plastics, fabrics, metals and the like. Plastic sheet material, such as polyethylene and polypropylene are preferred for the manufacture of side panels 21, top panel 30 and bottom panel 36. It is understood that this sheet material can be rigid or flexible. Panels 21, 30 and 36 can be clear, or constructed of materials selected from the group consisting of opaque materials, UV blocking materials and mixtures thereof. As shown in Figure 1, treatment bag 10 has an opaque mid portion 27, which has a mid portion height 18, a clear bottom portion 29, which has a lower portion height 20, and a clear upper portion 31, which has an upper portion height 16. Figure 5 illustrates a treatment bag 100 wherein the mid portion 42 is clear, as is the remainder of the bag.

Those skilled in the art will recognized that essentially all fabrics fade to a certain extent in the presence of UV radiation, and to a lesser extent, when in the presence of visible light. And because one preferred embodiment of this invention requires that the treatment bag be subjected to solar radiation, which comprises both UV radiation and visible light, some protection against fading for the fabric articles is desirable. This protection against fading can be provided with a barrier material, such as a UV blocker or an opaque material. As used herein, "opaque material" means any material, for example, cloth, plastic, thin metal, coatings, for example, sun screen materials and paints, and others, that reflects or absorbs at least about 50%, more preferably 75%, and most preferably 90% of the UV radiation, visible light or both that impinges on it. The entire treatment bag can be made of the barrier material or only a portion as shown in Figure 1. UV blocking materials will be known to those skilled in the art, on such example is polyethylene napthalate, "PEN".

Fabric treatment bag 10 optionally further comprises an upper frame 28, a bottom frame 34 and a side frame 25. These frames can be separate from one another, or they can be a unitary structure. One or more of these frames can be absent, although upper frame 28 is highly preferred. Rigid side panels can be employed to construct the treatment bags of this invention, and hinges can be used to make the treatment bag collapsible.

If a frame is employed, preferably the frames form a flexible, collapsible frame that when expanded forms a semi-rigid, three dimensional structure. Examples of collapsible structures are known, for example, in U.S. Patent No. 5,038,812, which issued on August 13, 1991, to Norman. The entire disclosure of the Norma patent is incorporated herein by reference. In general, flexible, collapsible frames, such as those found in Norman, are formed from material that is relatively strong but nevertheless flexible enough to allow it to be collapsed. An exemplary frame material is flat spring steel having a rectangular cross section with dimensions of 1.6mm in width and 76mm in length. The frame or frames can be sewn, glued or otherwise attached to the interior or the exterior of the treatment bag. Likewise, the frame or frames can be free standing with the treatment bag material hanging loosely over, or being expanded by the frame.

Referring now to Figure 3, which is a cut away view of the lower portion 29 of treatment bag 10, a substrate 40 is shown overlying optional supplemental heat source 50. Substrate 40 is one preferred method of supplying the cleaning refreshing composition, which is releasably absorbed therein, to the interior chamber 23 of treatment bag 10. Other methods of adding the cleaning refreshing composition to the treatment bag 10 include direct application and dosing devices that are known to the art, and additional methods will be apparent to those skilled in the art. Optional supplemental heat source 50 can be, for example, heat cells comprising a particulate exothermic composition as described below. Moreover, supplemental heat source 50 can be a heat sink such as a dark material that absorbs solar radiation thereby increasing its surface temperature, which in turn increases the temperature of substrate 40 that contains the cleaning refreshing composition. Supplemental heat source 50 can be any appropriate size. But if it is intended that supplemental heat source 50 is to absorb solar radiation, supplemental heat source 50 should have a larger surface area than does substrate 40. This will allow at least a portion of supplemental heat source 50 to extend beyond the edges of substrate 40 if substrate 40 is laid directly on top of supplemental heat source 50.

Referring now to Figure 4, in one preferred embodiment of this invention treatment bag 10 further comprises a pouch 54 for receiving the cleaning refreshing composition. The cleaning refreshing composition can be poured directly into the pouch 54, or more preferably, the cleaning refreshing composition is releasably absorbed into a substrate 40, which is placed in pouch 54. Pouch 54 can be in the interior chamber 23 of treatment bag 10, or it can be on the exterior of treatment bag 10, but pouch 54 is preferably on a side panel 21 so as to improve the exposure of the cleaning refreshing composition to solar radiation 60. Regardless, pouch 54 should be in fluid communication with the interior chamber 23 of fabric treatment bag 10 so that the vaporized cleaning refreshing composition intermingles with the fabric articles suspended in treatment bag 10. Pouch 54 is shown in Figure 4 with an optional supplemental heat source 52, which can be, for example, a dark material that absorbs solar radiation thereby increasing the surface temperature of the supplemental heat source 52, and in turn heating substrate 40 that contains the cleaning refreshing composition. Supplemental heat source 52 can also be a heat cell containing a particulate exothermic composition as described below.

In preferred embodiments of the treatment bags of the present invention at least one vent is used, but, as described below, the vent need not be a separate element. Upper vents 32 are shown in figures 1, 2 and 5, while lower vents 38 are shown in Figures 1 through 4. Vents 32 and 38 are shown adjacent top panel 30 and bottom panel 36, respectively, but this invention is not meant to be so limited. The vent can be at any location on the side panels 21, and the vent need not be a separate element. Specifically, treatment bag 10 can be vented by natural leakage through seams and seals, such as the seal 17 around opening 15. Alternatively, a completely sealed interior chamber can be employed, particularly to increase the interior chamber temperature or vapor concentration.

Fabric articles can be suspended in the inter chamber 23 of treatment bag 10 by any appropriate method. One such method is shown in figure 1, 2 and 5 wherein a bar 24 is provided to suspend hangers 26. In one embodiment of this invention, substrate 40 can be suspended within treatment bag 10, for example, by draping substrate 40 over hanger 26. Treatment bag 10 can be free standing with the support of a rigid frame, as described above, or it can be suspended by a hanging member 22 from a support means (not shown). If treatment bag 10 is suspended by hanging member 22 no frame is required although frames are generally preferred to control and maintain the shape and volume of interior chamber 23.

Referring now to Figure 2, which is a schematic representation of fabric treatment bag 10, wherein a portion of one corner is cut away for a more complete view of substrate 40, solar radiation 60 is shown contacting side panel 21. As solar radiation 60 impinges on treatment bag 10 the "green house effect", which is a well known phenomenon, and radiant heat causes the temperature in the interior chamber 23 to increase. The increase in temperature causes the cleaning refreshing composition that is releasably absorbed onto substrate 40 to evaporate in the form of vapors 46. The increase in temperature also causes a "chimney effect", another notorious phenomenon, within interior chamber 23. The chimney effect causes outside air 44 to be drawn through lower vents 38, where it then mixes with the cleaning refreshing composition vapors 46, which are drawn off of substrate 40 traveling upwards through interior chamber 23 where the mixture of air and vapors intermingle with any fabric articles, such as garments 33 shown in Figure 5, suspended therein. The air/vapor mixture 48 is then vented to the atmosphere via upper vents 32. Air/vapor mixture 48 will typically include malodorous compounds from the fabric articles, for example cigarette smoke, and other volatile compounds that may be present on the fabric articles. Treatment bag 100, as shown in Figure 5, operates in much the same way as described above only without vents in bottom panel 36.

A second substrate 40 is shown in Figure 2 draped over hanger 26 near the upper portion 31 of treatment bag 10. It is understood that single or multiple substrates that releasably contain the cleaning and refreshing compositions of this invention can be used in the fabric treatment processes described herein. Moreover, the substrates can be placed virtually anywhere in the treatment bag or adjacent the exterior of the treatment bag as described above. Figure 2 also shows an alternative access panel 19 for accessing the interior chamber of treatment bag 10.

Turbulent air flow through the fabric articles, such as garments 33 shown in Figure 5, may improve the fabric-to-air contact resulting in improved malodor removal from the fabric articles. Turbulent air flow can be achieved by any of a variety of methods that will be known to those skilled in the art. Examples of methods that can produce turbulence within the interior chamber of a treatment bag include: special bag designs; baffles within the bag; fans that are powered by battery, solar cells or other available power sources; or a fan that is powered by the rising warm air generated by the "chimney effect" discussed above.

Heat Sources

The treatment bag of this invention generally requires a supplemental heat source, and preferably that heat source is passive. By "passive" it is meant that the heat source is not provided by a mechanical, electrical or combustion source. Supplemental heat sources that are not passive but are contemplated for use with the present invention include, for example, a conventional hair dryer that is partially inserted in the treatment bag and operated to provide a warm air flow in the treatment bag. Solar radiation and exothermic chemical sources are especially preferred passive heat sources. Preferred exothermic chemical sources can be provided from, for example, a particulate exothermic composition that comprises iron powder, carbon, a metal salt(s), and water.

Heat cells that comprise a particulate exothermic composition are described in U.S. Patent Application No. 08/604,694, filed February 21, 1996, in the name of Timothy Alan Burkett, which is entitled HEAT CELLS. The entire disclosure of Application No. 08/604,694 is incorporated herein by reference. As described above, Figure 3 is a partial schematic representation of lower portion 29 of fabric treatment bag 10 wherein a supplemental heat source 50 is laid under substrate 40. Supplemental heat source 50 can be, for example, one or more of the Heat Cells disclosed in U.S. Patent Application 08/604,694. One preferred particulate exothermic composition comprises iron powder, carbon, at least one metal salt, and water. Each of these components are described in greater detail below.

Iron Powder

Iron is the anode for the electrochemical reaction involved in the exothermic oxidation of iron. Suitable sources for iron powder include cast iron powder, reduced iron powder, electrolytic iron powder, scrap iron powder, pig iron, wrought iron, various steels, iron alloys, and the like and treated varieties of these iron powders. There is no particular limitation to their purity, kind, etc. so long as it can be used to produce heat-generation with electrically conducting water and air.

Typically, the iron powder comprises from about 30% to about 80% by weight, preferably from about 50% to about 70% by weight, of the particulate exothermic composition of the present invention.

While oxygen is necessary for the oxidation reaction of iron to occur, an internal oxygen source is not required in the heat cells of the present invention, however, oxygen-producing chemical materials may be incorporated in the particulate exothermic composition at the time of preparation thereof without changing the scope of the present invention. The oxygen sources used for the purpose of this invention include air and artificially made oxygen of various purity. Among these oxygen sources, air is preferred since it is the most convenient and inexpensive.

Activated and Non-activated Carbon

Activated carbon serves as the cathode for the electrochemical reaction involved in the exothermic oxidation of iron. Active carbon is extremely porous in the inner structure giving it particularly good water-retention capabilities. Moreover, active carbon not only absorbs water well, but also adsorbs water vapor evaporated by the heat generation of the exothermic composition and helps prevent the escape of the water vapor. Therefore, it can also serve as a water-holding material. Further, active carbon can adsorb odors such as those caused by the oxidation of iron powder.

Active carbon prepared from coconut shell, wood, charcoal, coal, bone coal, etc. are useful, but those prepared from other raw materials such as animal products, natural gas, fats, oils and resins are also useful in the heat cells of the present invention. There is no limitation to the kinds of active carbon used, however, the preferred active carbon has superior water holding capabilities. The cathode capabilities can be extended by using non-activated carbon powder, i.e., carbon blended to reduce cost. Therefore, mixtures of the above carbons are useful in the present invention as well.

Typically, activated carbon, non-activated carbon, and mixtures thereof, comprises from about 3% to about 25%, preferably from about 8% to about 20%, most preferably from about 9% to about 15% by weight, of the exothermic compositions of the present invention.

Metal Salts

The metal salt serves as a reaction promoter for activating the surface of the iron powder to ease the oxidation reaction with air and provides electrical conduction to the exothermic composition to sustain the corrosive reaction. Useful metal salts include sulfates such as ferric sulfate, potassium sulfate, sodium sulfate, manganese sulfate, magnesium sulfate; and chlorides such as cupric chloride, potassium chloride, sodium chloride, calcium chloride, manganese chloride, magnesium chloride and cuprous chloride. Also, carbonate salts, acetate salts, nitrates, nitrites and other salts can be used.

Among these metal salts, the deliquescent salts such as calcium chloride, magnesium chloride, etc. are very hygroscopic and hence these compounds, even when added in a small amount, show an effectiveness in inhibiting the escape of water vapor. Sodium chloride shows small solubility difference vs. temperature difference and hence no crystal is precipitated at low temperatures, and also provides reasonable heat-generation. Thus, deviation of heat-generation due to temperature difference of atmospheric air does not occur. In general, several suitable alkali, alkaline earth, and transition metal salts exist which can also be used, alone or in combination, to sustain the corrosive reaction of iron.

The preferred metal salts of the present invention are sodium chloride, cupric chloride, and mixtures thereof.

Typically, the metal salt(s) comprises from about 0.5% to about 10% by weight, preferably from about 1.0% to about 5% by weight, of the particulate exothermic composition of the present invention.

Water

The water used herein may be from any appropriate source. There is no particular limitation to its purity, kind, etc. Typically, water comprises from about 1% to about 40% by weight, preferably from about 10% to about 30% by weight, of the particulate exothermic composition of the present invention. Additional Components

In addition to the above described components of the particulate exothermic compositions of the present invention, other components may also be added as appropriate.

Additional water-holding materials absorb the aqueous solution of reaction promoter, as does carbon, and serves the function of gradually supplying the promoter and water to the coexistent iron powder. Useful additional water-holding materials include vermiculite, porous silicates, wood powder, wood flour, cotton cloth having a large amount of fluffs, short fibers of cotton, paper scrap, vegetable matter, super absorbent water-swellable or water-soluble polymers and resins, carboxymethylcellulose salts, and other porous materials having a large capillary function and hydrophilic property can be used.

Typically, the additional water-holding materials comprise from about 0.1% to about 30% by weight, preferably from about 0.5% to about 20% by weight, most preferably from about 1% to about 10% by weight, of the particulate exothermic composition of the present invention.

Other additional components include oxidation reaction enhancers such as elemental chromium, manganese, or copper, compounds comprising said elements, or mixtures thereof; hydrogen gas inhibitors such as inorganic or organic alkali compounds or alkali weak acid salts including sodium hydroxide, potassium hydroxide, sodium hydrogen carbonate, sodium carbonate, calcium hydroxide, calcium carbonate, and sodium propionate; fillers such as natural cellulosic fragments including wood dust, cotton linter, and cellulose, synthetic fibers in fragmentary form including polyester fibers, foamed synthetic resins such as foamed polystyrene and polyurethane, and inorganic compounds including silica powder, porous silica gel, sodium sulfate, barium sulfate, iron oxides, and alumina; and anti-caking agents such as tricalcium phosphate and sodium silicoaluminate. Such components also include thickeners such as cornstarch, potato starch, carboxymethylcellulose, and α-starch, and surfactants such as those included within the anionic, cationic, nonionic, zwitterionic, and amphoteric types. The preferred surfactant, if used however, is nonionic. Still other additional components which may be added to the particulate exothermic compositions of the present invention, as appropriate, include extending agents such as metasilicates, zirconium, and ceramics. Particle Size Range

Preferably at least 50%, more preferably 70%, even more preferably 80% and most preferably 90% of all of the particles by weight of the particulate exothermic composition of the present invention have a mean particle size of less than 200 μm, preferably less than 150 μm.

Blending Ingredients

The above-mentioned components of the composition are blended while being isolated from air using conventional blending techniques. Suitable methods of blending these components are described in detail in U. S. Patent 4,649,895 to Yasuki et al., issued March 17, 1987 which is incorporated by reference herein.

The particulate exothermic composition can be contained in any appropriate container such as those described the described in the aforementioned U.S. Patent 4,649,895, already incorporated herein by reference. The finished heat cell is packaged in a secondary air- impermeable package to prevent the oxidation reaction from occurring until desired as is also described in U.S. Patent 4,649,895. Alternatively, air impermeable removable adhesive strips can be placed over the aeration holes in the heat cells such that, when the strips are removed, air is allowed to enter the heat cell, thus activating the oxidation reaction of the iron powder.

Cleaning/Refreshment Composition

The cleaning/refreshment composition preferably comprises water and a member selected from the group consisting of surfactants, perfumes, preservatives, bleaches, auxiliary cleaning agents, shrinkage reducing compositions, organic solvents and mixtures thereof. The preferred organic solvents are glycol ethers, specifically, methoxy propoxy propanol, ethoxy propoxy propanol, propoxy propoxy propanol, butoxy propoxy propanol, butoxy propanol, ethanol, isopropanol and mixtures thereof. Fabric shrinkage reducing compositions that are suitable for use in the present invention are selected from the group consisting of ethylene glycol, all isomers of propanediol, butanediol, pentanediol, hexanediol and mixtures thereof. More preferably, the fabric shrinkage reducing compositions are selected from the group consisting of neopentyl glycol, polyethylene glycol, 1,2-propanediol, 1,3-butanediol, 1-octanol and mixtures thereof. The surfactant is preferably a nonionic surfactant, such as an ethoxylated alcohol or ethoxylated alkyl phenol, and is present at up to about 2%, by weight of the cleaning/refreshment composition. Typical fabric cleaning/refreshment compositions herein can comprise at least about 80%, by weight, water, preferably at least about 90%, and more preferably at least about 95% water.

The Examples below give specific ranges for the individual components of preferred cleaning/refreshment compositions for use herein. A more detailed description of the individual components of the cleaning/refreshment compositions, that is, the organic solvents, surfactants, perfumes, preservatives, bleaches and auxiliary cleaning agents can be found in U.S. Patent No. 5,789,368, which issued on August 4, 1998 to You et al. The entire disclosure of the You et al. patent is incorporated herein by reference. Additionally, cleaning/refreshment compositions are described in co-pending U.S. Patent Application No. 08/789,171, which was filed on January 24, 1997, in the name of Trinh et al. The entire disclosure of the Trinh et al. Application is incorporated herein by reference. And shrinkage reducing compositions for use in this invention can be found in co-pending U.S. Provisional Application No. 60/ , entitled "Cleaning

Compositions that Reduce Fabric Shrinkage", which was filed by Strang and Siklosi, on August, 24, 1998. The entire disclosure of the Strang and Siklosi application is incorporated herein by reference.

Substrate

In one embodiment of this invention the cleaning/refreshment composition can be releasably absorbed in an absorbent substrate, herein after referred to as a "substrate". The substrate releasably contains the composition. By "releasably contains" means that the composition is effectively released from the substrate onto the soiled fabrics as part of the cleaning and fabric refreshment processes herein. This release occurs mainly by volatilization of the composition due to the heat from the supplemental heat source.

The substrate can be in any desired form, such as powders, flakes, shreds, and the like. However, it is highly preferred that the substrate be in the form of an integral pad or "sheet" that substantially maintains its structural integrity throughout the process. The substrates and sheets of this invention are sometimes referred to in the literature as "carriers" or "absorbent carrier sheets"; it is understood that all of these labels refer to liquid absorbing materials that can be used to conveniently transport liquids. Such substrates are described in detail in U.S. Patent No. 5,789,368, to You et al. which was incorporated herein by reference above. The manufacture of these sheets forms no part of this invention and is already disclosed in the literature. See, for example, U.S. Patents 5,009,747, Viazmensky, et al., April 23, 1991 and 5,292,581, Viazmensky, et al., March 8, 1994, which are incorporated herein by reference. The substrate is intended to contain a sufficient amount of the cleaning/refreshment composition to be effective for the intended purpose. The capacity of the substrate for such a composition will vary according to the intended usage. The size of the substrate should not be so large as to be unhandy for the user. Typically, the dimensions of the substrate will be sufficient to provide a macroscopic surface area (both sides of the substrate) of at least about 360 cm preferably in the range from about 360 cm^ to about 3000 cmA For example, a generally rectangular substrate may have the dimensions (X-direction) of from about 10 cm to about 35 cm, and (Y-direction) of from about 18 cm to about 45 cm.

In one preferred embodiment of this invention, the substrate is either a dark material, or is covered with a dark material, such as a black fabric. It is well known that dark materials absorb heat better than whiter materials. Thus, a dark substrate would tend to absorb more heat and volatilize more cleaning and refreshing composition if, for example, solar radiation is used as the supplemental heat source. As discussed, the substrate can optionally be covered with a coversheet as described below.

Coversheet

The coversheets employed herein are distinguished from the substrate, inasmuch as the coversheets are relatively non-absorbent to the cleaning/refreshment composition as compared with the substrate. The coversheets are constructed from hydrophobic fibers which tend not to absorb, "wick" or otherwise promote the transfer of fluids. While fluids can pass through the void spaces between the fibers of the coversheet, this occurs mainly when excessive pressure is applied to the article. Thus, under typical usage conditions the coversheet provides a physical barrier which keeps the absorbent substrate, which is damp from its load of cleaning/refreshment composition, from coming into direct contact with the fabrics being treated. Yet, the coversheet does allow vapor transfer of the cleaning/refreshment composition from the substrate through the coversheet and into the fabric treatment bag, and thus onto the fabrics being treated. If desired, the coversheet can be provided with macroscopic fenestrations through which the lint, fibers or particulate soils can pass, thereby further helping to entrap such foreign matter inside the article, itself.

Such fibrous, preferably heat resistant and, most preferably, hydrophobic, coversheets are described in detail in U.S. Patent No. 5,789,368, to You et al. which was incorporated herein by reference above. Additionally, co-pending U.S. provisional application 60/077,556, which was filed on March 11, 1998, in the name of Wise et al., describes certain improvements to the coversheets of this invention. The entire disclosure of the Wise et al. application is incorporated herein by reference. Suitable combinations of the coversheets described in You et al. with the improvements described in Wise et al. can be employed, according to the desires of the manufacturer, without departing from the spirit and scope of the invention.

Spot Cleaning Composition

The user of the present process can be provided with various spot cleaning compositions to use in the optional pre-spotting procedure of this invention. These compositions are used to remove localized stains from the fabrics being treated, either before or after the cleaning and refreshing process defined herein. Necessarily, the spot cleaning composition must be compatible with the fabric being treated. That is, no meaningful amount of dye should be removed from the fabric during the spot treatment and the spot cleaning composition should leave no visible stains on the fabric. Therefore, in a preferred aspect of this invention there are provided spot cleaning compositions which are substantially free of materials that leave visible residues on the treated fabrics. This necessarily means that the preferred compositions are formulated to contain the highest level of volatile materials possible, preferably water, typically about 95%, preferably about 97.7%, and surfactant at levels of about 0.1% to about 0.7%. A preferred spot cleaning composition will also contain a cleaning solvent such as butoxy propoxy propanol (BPP) at a low, but effective, level, typically about 1% to about 4%, preferably about 2%.

Preferred spot cleaning compositions are exemplified below, and are described in U.S. Patent No. 5,789,368, to You et al. which was incorporated herein by reference above. Additionally, spot cleaning compositions are described in U.S. Patent No. 5,630,847, which issued on May 20, 1997, to Roetker. The entire disclosure of the Roetker patent is incorporated herein by reference.

Treatment Member

In one embodiment, a treatment member is provided to assist in removing localized stains from fabrics. In a preferred aspect of this invention, the spot cleaning composition is provided in a dispenser, such as a bottle, and the dispenser has a distal tip that can serve as the treatment member. Additionally, the treatment member can comprise an absorbent base material which can be, for example, a natural or synthetic sponge, an absorbent cellulosic sheet or pad, or the like. In contact with and extending outward from this base material can be multiple protrusions. Specific examples of treatment members can be found in U.S. Patent No. 5,789,368, to You et al. which was incorporated herein by reference above.

Absorbent Stain Receiving Article

An absorbent stain receiving article, sometimes referred to herein as a stain receiver, can optionally be used in the optional pre-spotting operations herein. Such stain receivers can be any absorbent material which imbibes the liquid composition used in the pre-spotting operation. Disposable paper towels, cloth towels such as BOUNTY™ brand towels, clean rags, etc., can be used. However, in a preferred mode the stain receiver is designed specifically to "wick" or "draw" the liquid compositions away from the stained area. One preferred type of stain receiver consists of a nonwoven pad, such as a thermally bonded air laid fabric ("TBAL"). Another highly preferred type of stain receiver for use herein comprises polymeric foam, wherein the polymeric foam comprises a polymerized water-in-oil emulsion, sometimes referred to as "poly- HIPE". The manufacture of polymeric foam is very extensively described in the patent literature; see, for example: U.S. Patent No. 5,260,345 to DesMarais, Stone, Thompson, Young, LaVon and Dyer, issued November 9, 1993; U.S. Patent No. 5,550,167 to DesMarais, issued August 27, 1996, and U.S. 5,650,222 to DesMarais et al., issued July 22, 1997, all incorporated herein by reference. Typical conditions for forming the polymeric foams of the present invention are described in co-pending U.S. Patent Application Serial No. 09/042,418, filed March 13, 1998 by T. A. DesMarais, et al., titled "Absorbent Materials for Distributing Aqueous Liquids", the disclosure of which is incorporated herein by reference. Additional disclosure of conditions for forming the polymeric foams for use in the present invention are described in co- pending U.S. Provisional Patent Application Serial No. 60/077,955, filed March 13, 1998 by T. A. DesMarais, et al., titled "Abrasion Resistant Polymeric Foam And Stain Receivers Made Therefrom", the disclosure of which is incorporated herein by reference.

The various stain receivers described herein, and described in the references incorporated herein by reference, preferably comprise a liquid impermeable backsheet. The backsheet can be made of, for example, a thin layer of polypropylene, polyethylene and the like. The backsheet provides protection for the surface that the stain receiver rests on from the spot cleaning composition. For example, spot cleaning processes are typically performed on a hard surface, such as a table top. The stain receiver is placed on the table and the fabric to be treated in placed on the stain receiver. Spot cleaning composition is applied to the stained area of the fabric and then drawn into the stain receiver. But in the absence of a back sheet, the spot cleaning composition can leak onto the table top, possibly causing damage thereto.

While the backsheet preferably covers only one side of the absorbent stain receiver, leaving the opposite side exposed to receive the spot cleaning solution, the back sheet may extend over the edges of the receiver to protect against leakage of the spot cleaning solution from the edges of the stain receiver. But extending the backsheet over the edges and onto the absorbing side of the receiver minimizes the surface area available for receiving the spot cleaning solution. One solution to this paradox is to have a portion of the back sheet extend beyond one or more of the edges of the stain receiver in the form of "wings". The wings provide additional protection by insuring that the spot cleaning composition is contained if it leaks from the edges of the stain receiver, while simultaneously maximizing the absorbent surface area of the stain receiver.

Cleaning And Refreshing Processes

The cleaning/refreshment composition must enter the treatment bag either in vapor or liquid form. That is, the liquid composition can be adjacent to the exterior of the treatment bag as long as the vapors are free to enter the bag. Thus, the cleaning/refreshment composition is either added directly to the treatment bag by, for example: pouring or spraying the cleaning/refreshment composition directly into the bag; placing a substrate that releasably contains the cleaning/refreshment composition into the bag; placing the cleaning/refreshment composition in a vapor permeable dosing device that is placed in the bag; or placing the cleaning/refreshment composition adjacent the exterior of the treatment bag by any of the above methods such that the vapors from the cleaning/refreshment composition enter the interior chamber of the treatment bag. The fabric articles that are to be cleaned and refreshed can by placed in the treatment bag at any convenient time, that is, before, during or after the addition of the cleaning/refreshment composition.

To increase the temperature within the treatment bag, whereby the cleaning/refreshment composition is at least partially vaporized, the treatment bag is then subjected to a supplemental heat source. This can be accomplished by, for example: placing the treatment bag in an area where it is impinged upon by solar radiation; placing one or more heat cells in the treatment bag or adjacent the exterior of the treatment bag, such that the heat cells warm the cleaning/refreshment composition; partially inserting a conventional hair dryer into the treatment bag so as to blow warm air into the treatment bag; or by other methods of increasing the temperature within the treatment bag.

It is understood that the treatment bag can be hung from a support or it can be free standing. If it is free standing, it is generally preferred that it not be placed directly on the ground or other surfaces that can act as a heat sink. For example, a simple stand comprising legs and a base to support the treatment bag can be used to elevate the treatment bag from any surfaces that might absorb heat from the lower portion of the treatment bag.

The supplemental heat source creates a warm, humid environment inside the bag that volatilizes malodor components in the manner of a "steam distillation" process, and moistens fabrics and the soils thereon. This moistening of fabrics can loosen pre-set wrinkles, without setting of new wrinkles during the drying stage toward the end of the dryer cycle. Proper selection of the amount of the cleaning/refreshment composition, and specifically the amount of water used in the process and, importantly, proper venting of the bag in the present manner can minimize shrinkage of the fabrics. Moreover, if the bag is not vented, the volatilized malodorous materials removed from the fabrics can undesirably be re-deposited thereon.

In more detail, the cleaning and refreshing process herein can be conducted in the following manner. Modifications of the process can be practiced without departing from the spirit and scope of the present invention.

(i) optionally, conducting a pre-spotting process according to the description below, on localized stained areas of the fabric;

(ii) placing the entire fabric together with the cleaning/refreshment composition, preferably a substrate that releasably contains the composition in a fabric treatment bag;

(iii) subjecting the bag to a supplemental heat source that is preferably passive, and even more preferably selected from the group consisting of solar radiation a particulate exothermic composition and mixtures thereof; and

(iv) removing the fabric from the bag.

The treatment bag can be subjected to the supplemental heat source for any appropriate time. The time interval can be as short as about 10 minutes, or as long as a full day. For example, if solar radiation is used as the heat source the process can be conducted for as long as the sun is shining. Alternatively, if a different heat source is used a shorter time period may be appropriate. This step can be conducted for longer or shorter periods, depending on such factors as the degree and type of soiling of the fabrics, the nature of the soils, the nature of the fabrics, the fabric load, the amount of heat applied, and the like, according to the needs of the user.

In more detail, a pre-spotting process can be conducted in the following manner. Modifications of the process can be practiced without departing from the spirit and scope of the present invention.

1. Place a stained area of the fabric over and in contact with the poly-HIPE or TBAL stain receiver described herein or, less preferably, an ordinary folded paper towel (e.g., preferably white or non-printed - to avoid dye transfer from the towel - BOUNTY® brand) on any suitable surface such as a table top, in a tray, etc.

2. Apply enough spot cleaning composition from a dispenser bottle with a narrow spout which directs the composition onto the stain (without unnecessarily saturating the surrounding area of the fabric) to saturate the localized stained area - about 10 drops; more may be used for a larger stain.

3. Optionally, let the composition penetrate the stain for 3-5 minutes.

4. Optionally, apply additional composition - about 10 drops; more may be used for larger stains.

5. Use the treatment member, such as the distal tip on the dispenser bottle to work the stain completely out. Contact can be maintained for a period of 1-60 seconds for lighter stains and 1-5 minutes, or longer, for heavier or more persistent stains.

6. Optionally, blot the fabric, e.g., between paper towels, to remove excess composition. Or, the treated area can be blotted with a dampened sponge or other absorbent medium to flush the fibers and remove excess composition.

The following Examples further illustrate the invention, but are not intended to be limiting thereof.

EXAMPLE I Cleaning and Refreshing Compositions

Fabric cleaning/refreshment compositions according to the present invention, for use in a fabric treatment bag, are prepared as follows:

Ingredient % (wt.)

Emulsifier (TWEEN 20)* 0.5

Perfume 0.5

KATHON® 0.0003

Sodium Benzoate 0.1

Water Balance

"Polyoxyethylene (20) sorbitan monolaurate available from ICI Surfactants.

Additionally, preferred compositions for use in the fabric treatment bag of the process herein are as follows.

Ingredient % (wO Range (% wt.)

Water 99.0 95.1-99.9

Perfume 0.5 0.05-1.5

Surfactant* 0.5 0.05-2.0

Ethanol or Isopropanol 0 Optional to 4%

Solvent (e.g. BPP) 0 Optional to 4%

Hydrogen peroxide 0 Optional to 4% pH range from about 6 to about 8.

EXAMPLE II

Preparation Of A Substrate Comprising A Cleaning/Refreshment Composition

A 10 1/4 in. x 14 1/4 in. (26 cm x 36 cm) substrate in the form of a sheet is prepared from HYDRASPUN® material, manufactured by the Dexter Corp. The substrate sheet is covered on both sides with a topsheet and a bottomsheet of 8 mil (0.2 mm) Reemay fabric coversheet material. The coversheet (i.e., both topsheet and bottomsheet) are bonded to the substrate sheet by a Vertrod® or other standard heat sealer device, such as conventional sonic sealing devices, thereby bonding the laminate structure together around the entire periphery of the sheet. The edges of the sheet around its periphery are intercalated between the topsheet and bottomsheet by the bond. As noted above, the width of the bond is kept to a minimum and is about 0.25 in. (6.4 mm).

The bonded laminate sheet thus prepared is folded and placed in a pouch. Any plastic pouch which does not leak would be suitable. For example, a foil laminated pouch of the type used in the food service industry can be employed. Such pouches are well-known in the industry and are made from materials which do not absorb food flavors. In like manner, the formulator herein may wish to avoid absorption of the perfume used in the cleaning/refreshment composition by the pouch. Various pouches are useful herein and are commercially available on a routine basis.

The folded substrate/coversheet sheet is placed in the pouch. The folds can be of any type, for example, an accordion-style fold or rolled and then the roll is folded in half. The folded size is not critical but should be convenient for placement in a pouch.

23 grams of the cleaning/refreshment composition are poured onto the substrate sheet/coversheet, and the composition is allowed to absorb into the substrate. The pouch is sealed immediately after the liquid product is introduced into the pouch and stored until time-of- use.

EXAMPLE III Spot Cleaning Compositions

A spot cleaning composition for use in the present invention, preferably with a dispenser as defined above, and with a TBAL or poly-HIPE foam stain receiver, is prepared as follows:

INGREDIENT % (Wt.) fNonionic) Range % ( Wt.)

Hydrogen peroxide 1.000 0-2

Amino tris(methylene phosphonic acid)* 0.040 0-0.06

Butoxypropoxypropanol (BPP) 2.000 1-6

Neodol 23 6.5 0.250 0-1

Kathon preservative 0.0003 Optional**

Water 96.710 Balance pH target = 7; range = 6 - 8

* Stabilizer for hydrogen peroxide

** Sufficient to provide a preservative function. Another example of a preferred, high water content, low residue spot cleaning composition for use in the pre-spotting step herein is as follows. INGREDIENT Anionic Composition (%)

Hydrogen peroxide 1.000

Amino tris(methylene phosphonic acid)* 0.0400

Butoxypropoxypropanol (BPP) 2.000

NH Coconut E_jS 0.285

Dodecyldimethylamine oxide 0.031

Magnesium chloride 0.018

Magnesium sulfate 0.019

Hydrotrope, perfume, other minors, 0.101

Kathon preservative 0.0003

Water (deionized or distilled) 96.5

Target pH 6.0

* Stabilizer for hydrogen peroxide

Preferably, to minimize the potential for dye damage as disclosed hereinabove, H2O2- containing pre-spotting compositions comprise the anionic or nonionic surfactant in an amount (by weight of composition) which is less than the amount of H2O2. Preferably, the weight ratio of surfactant:H2θ2 is in the range of about 1 : 10 to about 1 : 1.5, most preferably about 1 :4 to about 1:3.

Another example of a preferred, high water content, low residue spot cleaning composition for use in the pre-spotting step herein is as follows.

INGREDIENT Anionic Composition (%)

Butoxypropoxypropanol (BPP) 2.000

NH₄ Coconut Ei S 0.285

Dodecyldimethylamine oxide 0.031

Magnesium chloride 0.018

Magnesium sulfate 0.019

Hydrotrope, perfume, other minors, 0.101

Kathon preservative 0.0003

Water (deionized or distilled) 97.5

Target pH 6.0

Claims

WHAT IS CLAIMED IS:

1. An apparatus for treating fabrics comprising: a) a fabric treatment bag having side panels configured such that they define an interior chamber of the treatment bag such that at least one fabric article can be suspended in the interior chamber; b) a liquid cleaning/refreshment composition; and c) a passive source of heat.

2. The apparatus according to claim 1, wherein the passive source of heat is selected from the group consisting of solar radiation, a particulate exothermic composition and mixtures thereof.

3. The apparatus according to claim 1, wherein the cleaning/refreshment composition comprises water and a member selected from the group consisting of surfactants, perfumes, preservatives, bleaches, auxiliary cleaning agents, shrinkage reducing compositions, organic solvents and mixtures thereof, preferably the organic solvents are glycol ethers, more preferably the organic solvents are selected from the group consisting of methoxy propoxy propanol, ethoxy propoxy propanol, propoxy propoxy propanol, butoxy propoxy propanol, butoxy propanol, ethanol, isopropanol and mixtures thereof.

4. The apparatus according to claim 1, wherein the cleaning/refreshment composition is releasably absorbed in a substrate.

5. The apparatus according to claim 1, further comprising a dosing device for containing the cleaning/refreshment composition.

6. The apparatus according to claim 2, wherein the particulate exothermic composition comprises iron powder, carbon, at least one metal salt, and water.

7. The apparatus according to claim 1 , wherein there is a portion of the side panels is constructed of materials selected from the group consisting of opaque materials, UV blocking materials and mixtures thereof.

8. The apparatus according to claim 1, wherein the fabric treatment bag further comprises a flexible, collapsible frame that when expanded forms a semi-rigid, three dimensional structure, preferably the treatment bag further comprises a pouch for receiving the cleaning refreshing composition, wherein the pouch is in fluid communication with the interior chamber of the fabric treatment bag, and even more preferably the fabric treatment bag further comprises at least one vent.

9. A non-immersion cleaning/refreshment process for treating a fabric article comprising the steps of:

(b) subjecting the fabric treatment bag to a passive source of heat; and

(c) removing the fabric from the fabric treatment bag.

10. The non-immersion cleaning/refreshment process of claim 9, wherein the cleaning refreshing composition is releasably absorbed in a substrate and it comprises water and a member selected from the group consisting of surfactants, perfumes, preservatives, bleaches, auxiliary cleaning agents, shrinkage reducing compositions, organic solvents and mixtures thereof, preferably the organic solvents are glycol ethers, more preferably the organic solvents are selected from the group consisting of methoxy propoxy propanol, ethoxy propoxy propanol, propoxy propoxy propanol, butoxy propoxy propanol, butoxy propanol, ethanol, isopropanol and mixtures thereof.

11. A process according to claim 9, wherein vapors are vented from the fabric treatment bag during step (b).

12. A process according to claim 10, wherein the fabric article and the substrate are suspended in the fabric treatment bag.

13. A process according to claim 9, wherein the fabric treatment bag further comprises a pouch for receiving the cleaning refreshing composition, wherein the pouch is in fluid communication with the interior chamber of the fabric treatment bag.

14. A process according to claim 9, wherein the fabric article has a first side and a second side and further comprising the steps of: